System and method for securely connecting portions of a composite structure together

ABSTRACT

A composite component assembly may include a composite core including a plurality of core cells between first and second ends. A connection joint is formed between the first and second ends. An adhesive layer is disposed within the connection joint between the first and second ends. The adhesive layer is configured to bond the first and second ends through a curing process. A peg splice securing joint securely connects the first and second ends together before and during the curing process.

RELATED APPLICATIONS

This application is a division of U.S. patent application Ser. No.14/940,397, entitled “System and Method for Securely Connecting Portionsof a Composite Structure Together,” filed Nov. 13, 2015, now U.S. Pat.No. ______, which, in turn, relates to and claims priority benefits fromU.S. Provisional Patent Application No. 62/142,767, entitled “System andMethod for Securely Connecting Portions of a Composite StructureTogether,” filed Apr. 3, 2015, which is hereby incorporated by referencein its entirety.

FIELD OF EMBODIMENTS OF THE DISCLOSURE

Embodiments of the present disclosure generally relate to systems andmethods for securely connecting portions of a composite structuretogether, and more particularly, to systems and methods for securelyconnecting portions of composite segments or portions together in orderto provide stability during a curing process.

BACKGROUND OF THE DISCLOSURE

Jet aircraft typically include one or more engines that may generatehigh levels of noise. For example, a fan case within a housing securedto a wing of an aircraft typically generates noise. Often, enginehousings include one or more sound dampening structures that are used toabsorb at least a portion of the noise generated by components of anengine. For example, an acoustic inlet barrel may be positioned at orproximate to an inlet of the engine housing upstream from a fan case.

Known acoustic inlet barrels are formed of composite materials, such ascarbon-reinforced plastics, that are sandwiched around an acoustic core,which may include a porous foam material. Each acoustic inlet barrel isgenerally formed of multiple pieces. For example, each acoustic inletbarrel may be formed of two or three pieces that are secured togetherthrough fasteners, such as bolts. Bulky bolt flanges are formed on thepieces and used to connect the pieces together with the separate anddistinct fasteners. However, the bolt flanges add mass to the acousticinlet barrel. Moreover, the process of securing the pieces together isgenerally labor and time intensive. Further, because each acoustic inletbarrel is formed from separate and distinct pieces that are securedtogether through fasteners, the integrity of the formed acoustic inletbarrel may be compromised through joints, seams, and the like betweenthe pieces. Also, the areas on and around the joints, seams, and thelike may exhibit less than optimal acoustical characteristics.

Certain known acoustic inlet barrels are formed through compositesandwich structures. A foaming adhesive is used to connect portions of acomposite sandwich structure together. For example, the compositesandwich structure may include a panel that is wrapped around a tool.Ends of the panel form a connection joint. The adhesive is positioned atthe connection joint. During a curing process, the adhesive reacts andadheres to the ends of the panel. As the adhesive cools and hardensduring or after the curing process, the hardened adhesive forms astructural bond that securely connects the ends of the panel together.

After the forming process, the connection joint is inspected to ensurethe integrity of the adhesive connection between the ends of the panel.A core splice gap width represents criteria for verifying the integrityof the adhesive connection. However, the forming process often rendersan inspection of the connection joint difficult, as the adhesiveconnection may be hidden by composite skins that have been cured to thecore.

In a typical foam adhesive splice, a gap between core segments may besubject to bondline depressions, which may form surface depressions incomposite skins. In some cases, the depressions may cause the componentto be rejected, which then results in considerable rework and/ordiscarding of the component.

Verifying an acceptable core splice gap width is accomplished by joiningsegments of core prior to bonding of composite skins. As such, the coresplices may be visually verified before being subjected to finalcomposite bonding. However, joining the segments in such a manner limitsprocess flexibility and typically requires a two-step cure process.

Another method of verifying core splice gap width is throughradiographic inspection. However, fabricating facilities may not haveradiographic equipment readily available. Further, radiographicequipment may be expensive and often requires regulatory approval andcertified technicians to operate.

Accordingly, a need exists for a system and method for efficiently,cost-effectively, and reliably connecting portions of a compositematerial together.

SUMMARY OF THE DISCLOSURE

Certain embodiments of the present disclosure provide a compositecomponent assembly that may include a composite core including aplurality of core cells between first and second ends. A connectionjoint may be formed between the first and second ends. An adhesive layermay be disposed within the connection joint between the first and secondends. The adhesive layer is configured to bond the first and second endstogether through a curing process. A peg splice securing joint securelyconnects the first and second ends together before and during the curingprocess.

The composite core may have a first height, and the peg splice securingjoint may have a second height that is less than the first height. In atleast one embodiment, the second height is less than 50% of the firstheight.

The peg splice securing joint may be urged into outer surfaces of thefirst and second ends. An outer surface of the peg splice securing jointmay be flush with the outer surfaces of the first and second ends.

The adhesive layer may be spaced apart from the peg splice securingjoint. The adhesive layer may include a foaming adhesive layer that isconfigured to react at and above a particular temperature.

Each of the plurality of core cells may include a septum having acousticproperties. The peg splice securing joint may be spaced apart from theseptum of each of the plurality of core cells.

The composite core and the peg splice securing joint may be formed ofthe same material, such as a honeycomb structure. The peg splicesecuring assembly may include a plurality of peg splice cells.

Certain embodiments of the present disclosure provide a method offorming a composite component assembly. The method may include laying-upa composite core having a plurality of core cells in relation to amandrel, disposing an adhesive layer within a connection joint betweenfirst and second ends of the composite core, securely connecting thefirst and second ends together with a peg splice securing joint, andcuring the composite component assembly. The securely connectingoperation securely fastens and stabilizes the first and second endstogether before and during the curing process. The curing operationcauses the adhesive layer to securely bond the first and second endstogether.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a perspective view of a composite core wrapped arounda mandrel, according to an embodiment of the present disclosure.

FIG. 2 illustrates a perspective top view of a peg splice securing jointpositioned over first and second ends of a composite core, according toan embodiment of the present disclosure.

FIG. 3 illustrates a lateral view of a peg splice securing jointpositioned on first and second ends of a composite core, according to anembodiment of the present disclosure.

FIG. 4 illustrates a top view of first and second ends of a compositecore before a peg splice securing joint is positioned thereon, accordingto an embodiment of the present disclosure.

FIG. 5 illustrates a lateral view of first and second ends of acomposite core securely connected together through a peg splice securingjoint and an adhesive layer, according to an embodiment of the presentdisclosure.

FIG. 6 illustrates a flow chart of a method of forming a compositecomponent assembly, according to an embodiment of the presentdisclosure.

FIG. 7 illustrates an internal view of an aircraft engine, according toan embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

The foregoing summary, as well as the following detailed description ofcertain embodiments will be better understood when read in conjunctionwith the appended drawings. As used herein, an element or step recitedin the singular and preceded by the word “a” or “an” should beunderstood as not necessarily excluding the plural of the elements orsteps. Further, references to “one embodiment” are not intended to beinterpreted as excluding the existence of additional embodiments thatalso incorporate the recited features. Moreover, unless explicitlystated to the contrary, embodiments “comprising” or “having” an elementor a plurality of elements having a particular property may includeadditional elements not having that property.

Embodiments of the present disclosure provide systems and methods forjoining segments of a composite core (of a composite sandwich structure)in such a way as to restrict inadvertent core movement during a curingprocess. Embodiments of the present disclosure include a peg splicelayer and an adhesive bonding splice between portions of the core orother such composite structure. The peg splice layer, which may be afraction of an overall core height, provides a mechanical lockingstructure that ensures geometrical integrity of the connection jointuntil an adhesive bonds the portions or segments of the core together.

Embodiments of the present disclosure provide systems and methods thateliminate, mitigate, or otherwise reduce a need for radiographicinspection of a core splice after a curing process. Additionally, thepeg splice layer creates a uniform bonding surface across core segments.The peg splice layer cooperates with an adhesive between componentsegments to create a bridge between the component segments, therebyavoiding a risk of surface depressions on the composite skins connectedto the peg splice layer.

Additionally, acoustically-treated core segments include core cellshaving septums. The septums may be formed from a wide range ofmaterials, and provide barriers that are formed in core cells at adesired height within a core. A partial height peg splice layer ensuresthat the peg splice layer does not interfere or disturb a septum,thereby maintaining acoustic properties of the core.

Certain embodiments of the present disclosure provide a honeycomb corecomposite panel that may include at least one first face sheet (forexample, a composite skin), a honeycomb core, and at least one secondface sheet (for example, another composite skin). The honeycomb core mayinclude at least two full depth core pieces spliced along at least oneedge, and at least one partial-depth core splice piece. A top surface ofthe partial depth splice piece may be flush with a top surface of eachof the full depth core pieces. The partial depth splice piece may beattached to the full depth core pieces by a plurality of lap joints, forexample. The partial depth splice piece may have a height (for example,a core thickness) less than a distance from a top surface of the twofull depth core pieces to an acoustical septum. In at least oneembodiment, the partial depth splice piece is less than 50% of thethickness of the full depth core pieces. Alternatively, the partialdepth splice piece may be greater than 50% of the thickness of the fulldepth core pieces, such as between 50%-70% of the thickness of the fulldepth core pieces.

Certain embodiments of the present disclosure provide a method ofmanufacturing a composite sandwich panel. The method may includeobtaining at least one face sheet (such as a composite skin), ahoneycomb core, and at least one second face sheet (such as anothercomposite skin). The method may also include (but does not require)laying up the first face sheet(s) on a mandrel, laying up the honeycombcore over the face sheet(s), and laying up the second sheet(s) over thehoneycomb core. The honeycomb core may include acoustical septums. Thehoneycomb core may include at least two spliced pieces attached througha partial depth core piece. The laying up of the core may includecompressing the two spliced pieces against the partial depth core pieceto attach the spliced pieces together.

Embodiments of the present disclosure provide systems and methods forefficiently, cost-effectively, and reliably holding together honeycombacoustical core pieces together before and during a curing process, andmaintaining part quality without sacrificing acoustical performance.Such goals are achieved by refraining from using an excessively thickzone of expanding adhesive and not disrupting acoustical membranes, suchas septums within cells of a composite core.

FIG. 1 illustrates a perspective view of a composite core 100 wrappedaround a mandrel 102, according to an embodiment of the presentdisclosure. The composite core 100 may include a composite panel 104having a first end 106 joined to a second end 108 at a connection joint110. The composite panel 104 may include a plurality of interconnectedhoneycomb cells 112. After the composite panel 104 is wrapped around themandrel 102, the ends 106 and 108 are securely connected together, asdescribed below. The mandrel 102 and the composite core 100 may then bepositioned within a curing chamber of a curing oven, for example, tofully form a composite component assembly that includes the compositecore 100.

In at least one embodiment, a face sheet (such as a composite skin) maybe wrapped around the mandrel 102 before the composite core 100 iswrapped around the mandrel 102. As such, the composite core 100 may bewrapped around the face sheet. After the composite core 100 is wrappedaround the mandrel, another face sheet (such as another composite skin)may be wrapped around an outer surface of the composite core 100.

One example of an embodiment of the mandrel 102 is described in U.S.patent application Ser. No. 14/588,465, entitled “System and Method ofForming a Component Using a Mandrel Assembly,” filed Jan. 2, 2015, whichis hereby incorporated by reference in its entirety.

In order to securely connect the first end 106 to the second end 108 atthe connection joint 110 before a curing process, a peg splice securingjoint (such as thinner piece of core material) is urged into at leastportions of the first and second ends 106 and 108, between which may bean adhesive layer, such as a foaming adhesive.

FIG. 2 illustrates a perspective top view of a peg splice securing joint200 positioned over the first and second ends 106 and 108 of thecomposite core 100, according to an embodiment of the presentdisclosure. It is to be understood that not all of the composite core100 is shown in FIG. 2. The composite core 100 includes a honeycombstructure having a plurality of hexagonal cells 112 interconnected toone another. Alternatively, the cells 112 may be various other shapes,such as squares, triangles, pentagons, octagons, or the like. Each cell112 includes a height 114.

An adhesive layer 201 is positioned between terminal edges 116 and 118of the first and second ends 106 and 108, respectively. The adhesivelayer 201 may be or include a planar piece (such as a ribbon, tape, orthe like) of foaming adhesive, which is configured to react at aparticular temperature, such as 350° F., in order to adhere and bond tosurfaces of the terminal edges 116 and 118. Alternatively, the reactiontemperature may be greater or less than 350° F.

In order to connect the first and second ends 106 and 108 together, theedge 116 of the first end 106 is urged into the edge 118 of the secondend 108, such as in the direction of arrow A. As the first and secondends 106 and 108 are urged into one another, the adhesive layer 201 istrapped and sandwiched between the edges 116 and 118. The first andsecond edges 116 and 118 may be joined to each other, such that cellpeaks 120 of the edge 116 of the first end 106 may nest into cellvalleys 122 of the edge 118 of the second end 108, while cell peaks 126of the edge 118 may nest into cell valleys 124 of the edge 116. Thefirst end 106 may interconnect to the second end 108 in various ways,such as through an interference fit that may or may not include nestedportions. As such, the first and second ends 106 and 108 may connecttogether through an interface connection, such as an interference fit, anested connection, a lap joint, an abutting connection, a compressiveconnection, and/or the like. Alternatively, other types of connectioninterfaces may be formed between the first and second ends 106 and 108.

After the first and second ends 106 and 108 are mated together, suchthat the adhesive layer 201 is sandwiched between the edges 116 and 118,the peg splice securing joint 200 is urged over top surfaces 130 and 132of the first and second ends 106 and 108, respectively, in the directionof arrows B, which may be orthogonal to the direction of arrow A. Assuch, the peg splice securing joint 202 forms a bridge over theconnection joint between the first and second ends 106 and 108.

The peg splice securing joint 200 may be formed of the same material asthe composite core 100. As such, the peg splice securing joint 200 mayinclude a plurality of interconnected honeycomb cells 202. Each cell 202may include a height 204 that is less than the height 114 of the cells112 of the composite core 100. For example, the height 204 may be lessthan 70% of the height 114 of the cells 112. In at least one embodiment,the height 204 may be less than 50% of the height 114. In at least oneother embodiment, the height 204 may be between 50%-70% of the height114. Alternatively, the height 204 may be greater than the 70% of theheight 114, but less than 100% of the height 114.

A width 206 of the peg splice securing joint 200 may be the same as awidth 140 of the composite core 100, and may be aligned with and overthe ends 106 and 108 so that respective upper and lower edges 208 and210 are aligned with and over respective upper and lower edges 142 and144 of the composite core 100. A length 212 of the peg splice securingjoint 200 exceeds a thickness of the adhesive layer 201, and may exceeda length of a cell 112. The greater the length 212, the greater thesecuring force exerted by the peg splice securing joint 200 into theends 106 and 108. However, if the length 212 is too large, the compositecore 100 may be overly rigid. As shown in FIG. 2, for example, the pegsplice securing joint 200 may be six cells long. Alternatively, thelength 212 may be greater or less than six cells wide. Also,alternatively, the width 206 of the peg splice securing joint 200 may beless than the width 140 of the composite core 100. In at least oneembodiment, a plurality of separate and distinct peg splice securingjoint segments may be positioned on the first and second ends 106 and108 along a connection joint therebetween.

FIG. 3 illustrates a lateral view of the peg splice securing joint 200positioned on the first and second ends 106 and 108 of the compositecore 100, according to an embodiment of the present disclosure. Asshown, the peg splice securing joint 200 bridges the first and secondends 106 and 108. The peg splice securing joint 200 may be positioned sothat half of its length is positioned over the first end 106, while theother half is positioned over the second end 108. The peg splicesecuring joint 200 may extend over two to four rows of cells 112 of eachof the first and second ends 106 and 108. Alternatively, the peg splicesecuring joint 200 may extend over less than two or more than four rowsof cells 112 of each of the first and second ends 106 and 108. Forexample, the peg splice securing joint 200 may extend over one and ahalf rows of cells 112 of each of the first and second ends 106 and 108.As another example, the peg splice securing joint 200 may extend overeight rows of cells 112 of each of the first and second ends 106 and108.

As shown, the adhesive layer 201 is sandwiched between the first andsecond ends 106 and 108. The adhesive 202 may extend from a level of abase 150 of the composite core 100 to a height 300 that is less thanheight 204 of the cells 202 of the peg splice securing joint 200. Assuch, when the peg splice securing joint 200 is urged downwardly intoand through the top surfaces 130 and 132 of the first and second ends106 and 108, respectively, the bottom of the peg splice securing joint200 may not extend into the adhesive layer 201, thereby ensuring thatthe adhesive layer 201 remains in position. Alternatively, the adhesivelayer 201 may extend to a height that is shorter or taller than shown.For example, the adhesive layer 201 may extend from the base 150 of thecomposite core 100 to a height that meets or exceeds the height 204 ofthe cells 202 of the peg splice securing joint 200. In at least oneother embodiment, the adhesive layer 201 may extend from the base 150 toa height of the composite core 100.

In order to securely connect the first end to the second end before acuring process, the peg splice securing joint 200 is urged into andthrough the top surfaces 130 and 132 of the first and second ends 106and 108. For example, a tool (such as a hammer, pneumatic actuator, orthe like) may be used to urge the peg splice securing joint 200 intoposition. The peg splice securing joint 200 may be urged downwardly inthe direction of arrow B until a top surface 220 of the peg splicesecuring joint 200 is flush with the top surfaces 130 and 132. Duringthe downward urging in the direction of arrow B, the peg splice securingjoint 200 and the composite core 100 may cut into each other, therebyforming a secure mechanical lock therebetween. In this manner, a secure,robust connection joint is formed between the first and second ends 106and 108 of the composite core. The peg splice securing joint 200stabilizes and secures the first and second ends 106 and 108 to oneanother before and during a curing process. In this manner, the pegsplice securing joint 200 stabilizes a connection joint between thefirst and second ends 106 and 108, such as by maintaining an interfacetherebetween within a desired tolerance. As such, during the curingprocess, the adhesive layer 201 reacts and ultimately forms a strong,secure adhesive bond between the first and second ends 106 and 108.

As shown, the cells 202 of the peg splice securing joint 200 do notfully extend through an entire height of the cells 112 of the compositecore 100. Accordingly, the cells 202 do not adversely affect acousticproperties of septums of the cells 112, even though portions of thecells 112 may be partially cut or sliced by the peg splice securingjoint 200. For example, septums 158 may be formed in each cell 112 up toa height 160 that is below a bottom surface 230 of the peg splicesecuring joint 200 when the top surface 200 is flush with the topsurfaces 130 and 132. The septums 158 may be formed from a wide range ofmaterials, and provide barriers within cells 112 at a desired heightwithin the composite core 100. Because the peg splice securing joint 200is not as tall as the composite core 100 (for example, the peg splicesecuring joint 200 is a “partial height” in relation to the cells 112),the peg splice securing joint 200 does not interfere or disturb theseptums 158, thereby preserving the acoustical properties of thecomposite core 100. Additionally, septums may be formed within the cells202 of the peg splice securing joint 200.

FIG. 4 illustrates a top view of the first and second ends 106 and 108of the composite core 100 before the peg splice securing joint 200(shown in FIGS. 2 and 3) is positioned thereon, according to anembodiment of the present disclosure. As noted, the adhesive layer 201(shown in FIGS. 2 and 3) is configured to be sandwiched between thefirst and second ends 106 and 108. The adhesive layer 201 is sandwichedwithin a splice gap width 400. A maximum splice gap width T_(max) is afunction of core cell geometry and core density. The maximum splice gapwidth T_(max) may be established based on standardized criteria. AfterT. is established, an appropriate grade of the adhesive layer 201, suchas a foaming adhesive, is applied to connection interfaces between thefirst and second ends 106 and 108. The first and second ends 106 and 108may connect to one another such that the adhesive layer 201 contacts anentire length of the edges 116 and 118 of the first and second ends 106and 108, respectively.

For example, if an adhesive such as BMSS-90 is used in the splice joint,T_(max) may differ based on the particular grade. For BMS5-90, Grade 25,T_(max) may be 0.025″. For BMS5-90, Grade 50, T_(max) may be 0.05″. ForBMS5-90, Grade 100, T_(max) may be 0.1″. Further, T_(max) values may beadditive, such that if two layers of Grade 50 are used, T_(max) may be0.1″. It is to be understood that the listed adhesives are merelyexamples, and are not limiting.

FIG. 5 illustrates a lateral view of the first and second ends 106 and108 of the composite core 100 securely connected together through thepeg splice securing joint 200 and the adhesive layer 201, according toan embodiment of the present disclosure. As shown, the top surface 220of the peg splice securing joint 200 may be flush, or substantiallyflush, with the top surfaces 130 and 132 of the first and second ends106 and 108 of the composite core 100. The bottom surface 230 of the pegsplice securing joint 200 may not abut into the adhesive layer 201 orthe septums 158 within the cells 112 of the composite core 100. That is,the peg splice securing joint 200 may not interfere with the adhesivelayer 201 or the septums 158. Alternatively, the peg splice securingjoint 200 may contact (for example, abut against, extend into, or thelike) at least a portion of the adhesive layer 201 and/or the septums158.

The peg splice securing joint 200 ensures that the first and second ends106 and 108 remain in a fixed, secure, and stable relationship withrespect to one another before and during a curing process. As such, thecomposite component assembly 500, which includes the composite core 100,the peg splice securing joint 200, and the adhesive layer 201, may bepositioned within a curing oven and cured, such that the adhesive layer201 reacts and ultimately bonds the first end 106 to the second end 108.The composite component assembly 500 may also include first and secondcomposite skins that sandwich the composite core 100 therebetween.

As shown in FIG. 5, the height 204 of the peg splice securing joint 200is less than 50% of the height 114 of the composite core 100. Forexample, the height 204 may be approximately 25% of the height 114.Alternatively, the height 204 may be greater or less than 25% of theheight 114. As the depth of height 204 increases, the height of theadhesive layer 201 may decrease so that the peg splice securing joint200 does not interfere with the adhesive layer 201.

FIG. 6 illustrates a flow chart of a method of forming a compositecomponent assembly, according to an embodiment of the presentdisclosure. The method may begin at 600, in which an inner sheet ofcomposite material (such as a first or inner composite skin) is laid uponto a mandrel. The inner sheet may be a single layer of compositematerial, which may include one or more plies of composite material.Next, at 602, a composite core is laid up over the inner sheet.Alternatively, 600 may be omitted, and the composite core may be laid upover the mandrel. At 606, a peg splice securing joint is aligned over aconnection joint between ends of the composite core. Then, at 608, thepeg splice securing joint is urged into the ends of the composite coreto securely connect the end together. At 610, an outer sheet ofcomposite material (such as a second or outer composite skin) is laid upover the composite core. Alternatively, 610 may be omitted. Then, at612, the formed composite component assembly is cured.

FIG. 7 illustrates an internal view of an aircraft engine 800, accordingto an embodiment of the present disclosure. The aircraft engine 800includes a main housing 802 that retains a fan 804, an engine 806, and acomposite component assembly 808, such as an acoustic inlet barrel,positioned proximate to an air intake inlet 810 of the aircraft engine800. The composite component assembly 808 may be formed as describedabove. The composite component assembly 808 may be secured to a fixtureassembly and machined before being secured within the main housing 802,such as described in U.S. patent application Ser. No. 14/588,468,entitled “System and Method of Securing a Component in Position forMachining Using a Fixture Assembly,” filed Jan. 2, 2015, which is herebyincorporated by reference in its entirety.

Alternatively, embodiments of the present disclosure may be used to formvarious other composite components, such as exhaust acoustic treatments,plugs, nozzles, thrust reversers, bypass ducts, and the like.

Referring to FIGS. 1-7, embodiments of the present disclosure providesystems and methods of forming a composite component assembly.Embodiments of the present disclosure provide systems and methods ofjoining segments of composite core that restrict core movement duringcuring processes. The core segments, such as ends of the core, may bepositioned according to guidelines established for T_(max) and foamingadhesive bondlines. An appropriate grade of foaming adhesive may beestablished per particular guidelines. Instead of applying the foamingadhesive to an entire height of the core segments, the foaming adhesivemay be trimmed such that a partial height peg splice securing joint maybe applied to one side of the splice joint and not interfere with thefoaming adhesive once fully embedded. Alternatively, the foamingadhesive may contact the peg splice securing joint. The peg splicesecuring joint provides a mechanical restraint and prevents the coresegments from moving relative to one another during a curing process.Accordingly, a compliant foaming adhesive core bond is formed that doesnot require post cure verification, due to the core splice gap beingmaintained throughout the curing process.

While various spatial and directional terms, such as top, bottom, lower,mid, lateral, horizontal, vertical, front and the like may be used todescribe embodiments of the present disclosure, it is understood thatsuch terms are merely used with respect to the orientations shown in thedrawings. The orientations may be inverted, rotated, or otherwisechanged, such that an upper portion is a lower portion, and vice versa,horizontal becomes vertical, and the like.

As used herein, a structure, limitation, or element that is “configuredto” perform a task or operation is particularly structurally formed,constructed, or adapted in a manner corresponding to the task oroperation. For purposes of clarity and the avoidance of doubt, an objectthat is merely capable of being modified to perform the task oroperation is not “configured to” perform the task or operation as usedherein.

It is to be understood that the above description is intended to beillustrative, and not restrictive. For example, the above-describedembodiments (and/or aspects thereof) may be used in combination witheach other. In addition, many modifications may be made to adapt aparticular situation or material to the teachings of the variousembodiments of the disclosure without departing from their scope. Whilethe dimensions and types of materials described herein are intended todefine the parameters of the various embodiments of the disclosure, theembodiments are by no means limiting and are exemplary embodiments. Manyother embodiments will be apparent to those of skill in the art uponreviewing the above description. The scope of the various embodiments ofthe disclosure should, therefore, be determined with reference to theappended claims, along with the full scope of equivalents to which suchclaims are entitled. In the appended claims, the terms “including” and“in which” are used as the plain-English equivalents of the respectiveterms “comprising” and “wherein.” Moreover, the terms “first,” “second,”and “third,” etc. are used merely as labels, and are not intended toimpose numerical requirements on their objects. Further, the limitationsof the following claims are not written in means-plus-function formatand are not intended to be interpreted based on 35 U.S.C. §112(f),unless and until such claim limitations expressly use the phrase “meansfor” followed by a statement of function void of further structure.

This written description uses examples to disclose the variousembodiments of the disclosure, including the best mode, and also toenable any person skilled in the art to practice the various embodimentsof the disclosure, including making and using any devices or systems andperforming any incorporated methods. The patentable scope of the variousembodiments of the disclosure is defined by the claims, and may includeother examples that occur to those skilled in the art. Such otherexamples are intended to be within the scope of the claims if theexamples have structural elements that do not differ from the literallanguage of the claims, or if the examples include equivalent structuralelements with insubstantial differences from the literal language of theclaims.

What is claimed is:
 1. A method of forming a composite componentassembly, comprising: disposing an adhesive layer within a connectionjoint between first and second ends of a composite core having aplurality of core cells; securely connecting the first and second endstogether with a peg splice securing joint; and curing the compositecomponent assembly, wherein the securely connecting securely fastens andstabilizes the first and second ends together before and during thecuring process, and wherein the curing causes the adhesive layer tosecurely bond the first and second ends together.
 2. The method of claim1, further comprising laying-up the composite core having the pluralityof core cells in relation to a mandrel before the disposing.
 3. Themethod of claim 1, wherein the composite core has a first height,wherein the peg splice securing joint has a second height that is lessthan the first height.
 4. The method of claim 1, wherein the secondheight is less than 50% of the first height.
 5. The method of claim 1,wherein the securely connecting comprises urging the peg splice securingjoint into outer surfaces of the first and second ends until an outersurface of the peg splice securing joint is flush with the outersurfaces of the first and second ends.
 6. The method of claim 5, whereinthe securely connecting comprises spacing the adhesive layer apart fromthe peg splice securing joint.
 7. The method of claim 1, wherein thecuring comprises causing the adhesive layer to adhere to portions of thefirst and second ends.
 8. The method of claim 1, wherein each of theplurality of core cells comprises a septum having acoustic properties.9. The method of claim 8, wherein the securely connecting comprisesspacing the peg splice securing joint apart from the septum of each ofthe plurality of core cells.
 10. The method of claim 1, furthercomprising forming the composite core and the peg splice securing jointof the same material.
 11. A method of forming a composite componentassembly, comprising: laying-up a composite core having a plurality ofcore cells in relation to a mandrel; disposing an adhesive layer withina connection joint between first and second ends of the composite core;and securely connecting the first and second ends together with a pegsplice securing joint, wherein the securely connecting comprises urgingthe peg splice securing joint into outer surfaces of the first andsecond ends until an outer surface of the peg splice securing joint isflush with the outer surfaces of the first and second ends.
 12. Themethod of claim 11, further comprising curing the composite componentassembly, wherein the securely connecting securely fastens andstabilizes the first and second ends together before and during thecuring process, and wherein the curing causes the adhesive layer tosecurely bond the first and second ends together.
 13. The method ofclaim 11, wherein the composite core has a first height, wherein the pegsplice securing joint has a second height that is less than the firstheight.
 14. The method of claim 11, wherein the second height is lessthan 50% of the first height.
 15. The method of claim 11, wherein thesecurely connecting comprises spacing the adhesive layer apart from thepeg splice securing joint.
 16. The method of claim 11, wherein thecuring operation comprises causing the adhesive layer to adhere toportions of the first and second ends.
 17. The method of claim 11,wherein each of the plurality of core cells comprises a septum havingacoustic properties.
 18. The method of claim 17, wherein the securelyconnecting comprises spacing the peg splice securing joint apart fromthe septum of each of the plurality of core cells.
 19. The method ofclaim 11, further comprising forming the composite core and the pegsplice securing joint of the same material.
 20. A method of forming acomposite component assembly, comprising: laying-up a composite corehaving a plurality of core cells in relation to a mandrel; disposing anadhesive layer within a connection joint between first and second endsof the composite core; and securely connecting the first and second endstogether with a peg splice securing joint, wherein the securelyconnecting comprises spacing the adhesive layer apart from the pegsplice securing joint.